Clutch Master Cylinder/Decat pipes

[jimed]

Just got back from a tour round Scotland - in the S of course!! - and have a couple of things I need to sort.
1 The clutch master cylinder. I replaced the rubbers some years ago and they have been Ok for several years (17K ago)so is it worth doing again (Lucas SP2102 is the kit no) or not? Any ideas - I suspect better to replace the cylinder? I've a part no for the cyl (Girling 64676310) but I've had a look on earlier forum posts and see that someone says the part no is the casting ref so anyone know a good part no for an S3 and ideas of best places to get one from?? (dealers are expensive for this sort of stuff)

2. I replaced the cats with decat pipes from TVR Car parts just before I went away and one of the pipes at the front of the exhaust underneath immediately behind the decat pipe is virtually touching the chassis member and the other does have a little more clearance but not much (and only because the front pipe on that side happens to have a small dinge in it where it has been shaped) - anyway as you can expect the exhaust sometimes rattles - pain in the proverbial - so I need to fix it. Maybe the answer is to send the pipes back to be checked as the cups at the ends did look as if they had been pressed a little deep but then how do I know?. (I've tried to measue the pipes v the old cats and they do seem to be a little shorter but it is very hard to tell and a small amount does make the difference). One idea could be to put a small dent in the pipes under the chassis to give clearance or some sort of a hard gasket/filler in the cup at one side, but that would need to be fairly hard so as not to squash up when tightened. Has anyone else had to do this ? Ideas how to put a small dent in the pipes? - would I need to heat them, - could it cause a problem with the profile, etc - they are stainless ...
Maybe the answer is to get them back to TVR Car parts but it would be 2 weeks off the road for replacements and a lot of messing about ...

Apart from that the car sounded great with the decat pipes and I think I also got a little more to the gallon than previously
Jim

[jonnylayze]

Can only help with the clutch - the Girling number is right but there are 3 different sizes and iirc you need the largest one. I got one which was a direct replacement for the one on the car and had problems. It seems that the master cylinder had previously been rpelaced but with a Girling cylinder on which the number matched but where the cylinder was of too small a bore. This was a mistake which I then repeated when the cylinder seals failed and although it did solve the problem at the time, once the clutch had been replaced as well (at a later date) I did encounter problems. The smaller cylinder did not offer enough travel to clear the clutch and the car was creeping as soon as it was in gear with the brake off. Using the bigger cylinder (with the same casting number cured this). So beware!!

[jimed]

Thanks Jonny. I have been sniffing round and you are right; I'm told the ref is the casting number and the cyls are available in 0.5, 0.7 and 0.75 ins bore. The standard fit is the 0.7 ins one but apparently the 0.75 would work just as well (and would presumably reduce the pedal travel slightly - could even be better??) whereas the 0.5 ins one wouldn't work the clutch enough to disengage it. All I need now is somewhere that does one at a good price, - any ideas anyone ...
Jim
PS By the way been speaking to Neil at TVR Car Parts; he has some exhaust olives that will sit in the decat pipe cups and drop the downpipes a bit so hopefully that will sort that without too much bother (This could be useful info for others I suspect ...)

[jonnylayze]

stupidly I can't remember what the correct size is but I reckon the bigger the better in order to give the pedal maximum adjustability.

I got mine from Merlin Motorsport at Castle Combe - cost just over £30. They do mail order too if you're not close by

[jimed]

Thanks Jonny I've sent them an email.
Jim